Hockey-stick blade with tailored performance regions

ABSTRACT

A hockey-stick blade includes a heel region, a toe region spaced longitudinally from the heel region, and a mid-region located between the heel region and the toe region. The toe region includes one or more reinforcing elements, optionally of different lengths, located at different vertical positions within the toe region. The blade further includes a hosel that optionally is tailored to substantially match the strength and stiffness characteristics of an attached or integral hockey stick shaft. The mid-region of the blade exhibits improved feel and flexibility characteristics due to the increased stiffness in the toe region.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/504,767 filed, Jul. 8, 2019, which is a continuation of U.S. patentapplication Ser. No. 15/869,412, filed Jan. 12, 2018, now U.S. Pat. No.10,350,470, which is a continuation of U.S. patent application Ser. No.14/720,639, filed May 22, 2015, now U.S. Pat. No. 9,868,038, which is acontinuation of U.S. patent application Ser. No. 13/688,061, filed Nov.28, 2012, now U.S. Pat. No. 9,039,549. All of these applications areincorporated fully herein by reference for any and all non-limitingpurposes.

BACKGROUND

Composite hockey-stick blades typically are constructed by wrappingfiber-reinforced plies over one or more elements to create ahockey-stick blade preform. The blade pre-form is then placed within anexternal mold where resin, which is either pre-impregnated in the fiberplies or added via a resin-transfer process, is cured. An expansionbladder within the blade pre-form, or one or more heat-expanding coreelements, may be used to provide internal pressure to mold the bladeinto the shape of the external mold. The curing process hardens theresin so that the fibers become disposed within a hardened resin matrix,while the mold defines the exterior shape of the cured blade (whichsometimes is integrally molded with a hockey-stick shaft).

The fibers in composite hockey-stick blades typically are orienteduniformly throughout the blade, which generally has a substantiallyuniform thickness. Some blades include separate elements that increasethe weight in the heel region or other portions of the blade to providevaried feel and control. The toe region of these blades, however, hasbeen ignored with respect to modifying weight and feel. Further, whileisolated regions in some composite blades have been modified, the bladesare not tailored throughout their lengths to provide tuned performanceand feel throughout the lengths of the blades.

SUMMARY

A hockey-stick blade includes a heel region, a toe region spacedlongitudinally from the heel region, and a mid-region located betweenthe heel region and the toe region. The toe region includes one or morereinforcing elements, optionally of different lengths, located atdifferent vertical positions within the toe region. The blade furtherincludes a hosel that optionally is tailored to substantially match thestrength and stiffness characteristics of an attached or integral hockeystick shaft. The mid-region of the blade exhibits improved feel andflexibility characteristics due to the increased stiffness in the toeregion. Other features and advantages will appear hereinafter. Thefeatures described above can be used separately or together, or invarious combinations of one or more of them.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein the same reference number indicates the sameelement throughout the various views:

FIG. 1 is a perspective view of a hockey stick according to oneembodiment.

FIG. 2 is a partial-perspective view of a hockey-stick blade with theexternal plies omitted to highlight internal features of the blade.

FIG. 3 is a sectional view of Section 3-3 of FIG. 2 .

FIG. 4 is a partial-perspective view of a hockey-stick blade with theface plies omitted to illustrate a serrated reinforcing ply in the toeregion of the blade.

DETAILED DESCRIPTION OF THE DRAWINGS

Various embodiments of the invention will now be described. Thefollowing description provides specific details for a thoroughunderstanding and enabling description of these embodiments. One skilledin the art will understand, however, that the invention may be practicedwithout many of these details. Additionally, some well-known structuresor functions may not be shown or described in detail so as to avoidunnecessarily obscuring the relevant description of the variousembodiments.

The terminology used in the description presented below is intended tobe interpreted in its broadest reasonable manner, even though it isbeing used in conjunction with a detailed description of certainspecific embodiments of the invention. Certain terms may even beemphasized below; however, any terminology intended to be interpreted inany restricted manner will be overtly and specifically defined as suchin this detailed description section.

Where the context permits, singular or plural terms may also include theplural or singular term, respectively. Moreover, unless the word “or” isexpressly limited to mean only a single item exclusive from the otheritems in a list of two or more items, then the use of “or” in such alist is to be interpreted as including (a) any single item in the list,(b) all of the items in the list, or (c) any combination of items in thelist.

Turning now in detail to the drawings, as shown in FIGS. 1-3 , a hockeystick 10 includes a blade 12 and a shaft 14. The blade 12 may bedetachable from the shaft 14 at its upper end, or it may be permanentlyor integrally attached to the shaft 14. The joint between the blade 12and the shaft 14 may be formed by a hosel 16 or tenon at the upper-endof the blade 12 that is received within a socket in the lower end of theshaft 14. Any other suitable connections between the blade 12 and theshaft 14, including those disclosed in U.S. Pat. Nos. 7,097,577 and7,144,343, for example, which are incorporated herein by reference, maybe used. The blade 12 and shaft 14 may be constructed in any suitablemanner, using any suitable materials, such as by those methods andmaterials described in incorporated U.S. Pat. Nos. 7,097,577 and7,144,343, while further incorporating one or more of the additionalfeatures described herein.

The blade 12 generally includes the upwardly extending hosel 16 andthree regions arranged in a longitudinal direction along the length ofthe blade: a heel region 20, a toe region 22, and a mid-region 24located between the heel region 20 and the toe region 22. As describedin detail below, each of these regions may be tailored to provideenhanced performance and feel characteristics throughout the blade.

The blade 12 includes a front face (not visible in the figures) and arear face 28 separated in a lateral direction by a cavity. The cavity isfilled with one or more core elements made of foam, elastomericmaterials, or one or more other suitable materials, such as thosedescribed in incorporated U.S. Pat. Nos. 7,097,577 and 7,144,343. Thecore elements are wrapped in one or more fiber reinforced plies, such asplies reinforced with carbon, aramid, boron, glass, or other suitablematerials, such as those described in incorporated U.S. Pat. Nos.7,097,577 and 7,144,343.

As shown in FIG. 2 , in the illustrated embodiment, the interior of theblade 12 includes four core elements 30, 32, 34, 36 generally runningfrom the toe region 22 to the heel region 20 of the blade 12. The coreelements optionally are separated from one another by three structuralribs 40, 42, 44 that also generally run from the toe to the heel of theblade 12. The ribs 40, 42, 44, which provide stiffness and structuralsupport to the blade 12, optionally are made of fiber-reinforcedmaterials that are integral with, adhered to, or otherwise affixed tothe front face and the rear face 28 of the blade. Any other suitablenumber of core elements and ribs may alternatively be used. In otherembodiments, a single core element may be used, such that no ribs areincluded. In still other embodiments, multiple core elements may be usedwithout the inclusion of ribs, such that the core elements abut oneanother or are spaced apart from one another.

In one embodiment, four core elements 30, 32, 34, 36 are each wrapped ina first ply including carbon fibers oriented at approximately 30°relative to the lateral direction between the front and rear bladefaces, and a second ply including carbon fibers oriented atapproximately −30° relative to this lateral direction. The two pliesoptionally may be combined into a single “sandwich ply,” in which thefirst ply is ironed to—or otherwise attached to or merged with—thesecond ply. A greater or lesser number of plies may be wrapped aroundeach of the core elements 30, 32, 34, 36, depending on the thickness ofthe core elements, the thickness of the plies, or the stiffness andflexibility goals of a given blade design.

The hosel 16 optionally extends a significant distance from the heelregion 20—and may even have a greater length than that of the blade 12from the toe region 22 to the heel region 20—as shown in FIG. 1 .Further, the hosel 16 preferably includes fibers oriented to approximatethe stiffness and strength characteristics of the shaft 14, such thatthe hosel 16 essentially is a structural extension of the shaft 14. Inone embodiment, the hosel 16 includes at least one first ply includingfibers oriented at approximately 90° relative to the lateral direction,and at least one neighboring second ply including fibers oriented atapproximately 0° relative to the lateral direction, which allows thehosel 16 to “blend in” with most composite hockey-stick shafts, whichtypically have similar fiber orientations. This blending creates a low“kick point” in the stick 10, which is desirable to many players. Aswith the plies wrapped around the core elements 30, 32, 34, 36, theplies in the hosel 16 optionally may be combined into one or moresandwich plies.

In one embodiment, the toe region 22 includes one or more reinforcingelements that enhance torque control and blade-tip “preloading” whenstriking a puck, ball, or other object (collectively referred to herein,for ease of description, as a “puck”). In this manner, the reinforcingelements reduce “lag” of the toe region 22, particularly during a “wristshot.” The reinforcing elements may include fiber reinforced plies,similar to those used to wrap the core elements 30, 32, 34, 36, or mayinclude other materials that stiffen the blade 12 in the toe region 22.For example, each reinforcing element may be a sandwich ply including“fibers oriented at 30° and −30°, or at 45° and −45°, relative to thelateral direction, or including fibers oriented at any other suitableangles.

These reinforcing plies may be positioned on, adhered to, or wrappedaround the plies that are wrapped around the core elements 30, 32, 34,36. In an alternative embodiment, the reinforcing elements may bedirectly positioned on, adhered to, or wrapped around the core elements30, 32, 34, 36 before the plies extending from the toe region 22 to theheel region 20 are wrapped around the core elements, such that thereinforcing elements are contained within these plies. Thus, thereinforcing elements may be indirectly or directly positioned on,adhered to, or wrapped around the core elements.

In the illustrated embodiment, a first reinforcing element 50 is wrappedaround the lower edge of the upper core element 30. A second reinforcingelement 52 is wrapped around the upper edge of the next core element 32,while a third reinforcing element 54 is wrapped around the lower edge ofthat core element 32. A fourth reinforcing element 56 is wrapped aroundthe upper edge of the next core element 34, while a fifth reinforcingelement 58 is wrapped around the lower edge of that core element 34.Finally, a sixth reinforcing element 60 is wrapped around the upper edgeof the lower core element 36.

A greater or lesser number of reinforcing elements may alternatively beincluded. For example, the two upper reinforcing elements 50, 52 may beomitted, such that four reinforcing elements 54, 56, 58, 60 are used.Further, the number of core elements could be varied such that a greateror lesser number of core-element surfaces, onto which reinforcingelements could be applied, would be exposed. Also, reinforcing elementscould be omitted from certain vertical positions to provide varied feeland performance.

In the illustrated embodiment, the first and second reinforcing elements50, 52 have substantially the same first length; the third and fourthreinforcing elements 54, 56 have substantially the same second length,which is longer than the first length; and the fifth and sixthreinforcing elements 58, 60 have substantially the same third length,which is longer than the second length. Arranging the reinforcingelements in this manner provides increasing stiffness in the toe region22 as the lower edge of the blade 12 is approached, which generallyprovides better performance and allows for better puck control. Each ofthe reinforcing elements alternatively could have substantially the samelength, or their lengths could increase as the upper edge of the bladeis approached. The individual reinforcing elements may be wrapped onlyaround the lower or upper region of a given core element, or they may bewrapped around an entire core element. In another embodiment, thereinforcing elements may additionally or alternatively be located on theribs between the core elements.

In one embodiment, the first length of reinforcing elements 50, 52 isapproximately 1.0 inch, while the second length of reinforcing elements54, 56 is approximately 2.5 inches, and the third length of reinforcingelements 58, 60 is approximately 4.0 inches. These reinforcing-elementlengths have been found to produce desirable performance and control inthe toe region 22, and also to provide better feel and control in themid-region 24, due to the increased stiffness in the toe region 22 whichresults in a feeling of increased flexibility in the mid-region 24. Anyother suitable reinforcing-element lengths may be used, however, to meetthe desired performance and feel characteristics of a given player.

The fiber-angles in any of the blade regions described above may bevaried based on desired performance and feel characteristics. Forexample, on the core elements 30, 32, 34, 36, a first ply includingcarbon fibers oriented at approximately 45° relative to the lateraldirection may be used in combination with a second ply including carbonfibers oriented at approximately −45°, 0°, or 90° relative to thelateral direction. Similar fiber angles could be used in the plies ofthe reinforcing elements, as well. Any other suitable combination offiber angles may alternatively be used.

Once the core elements are wrapped in fiber-reinforced plies, and thenreinforcing elements are positioned in the toe region 22, one or moreface plies may be wrapped around or otherwise applied to the front andrear surfaces of the wrapped core elements to form a blade pre-formstructure. The blade pre-form structure may include additional layers ofmaterial, such as one or more glass reinforced, serrated plies 70positioned around the toe region 22 to increase durability (as shown inFIG. 4 ), one or more layers of scrim cloth to reinforce the variousplies, and any other suitable materials. Once the blade pre-formstructure is completed, the blade may be cured using a bladder-moldingprocess, a compression-molding process, or in any other suitable manner,such as by those methods described, for example, in incorporated U.S.Pat. Nos. 7,097,577 and 7,144,343.

The hockey-stick blade 12 described herein provides several advantages.For example, by tailoring the hosel 16 to approximate the stiffness andstrength of the shaft 14, the hosel 16 essentially becomes an extensionof the shaft and allows for a lower “kick point,” which is preferred bymany players. By selectively stiffening portions of the toe region 22,pre-loading and torque control of the toe region 22 are enhanced, andlag is reduced, resulting in greater velocity and accuracy when shootinga puck, particularly during “wrist shots.” Further, by stiffening thetoe region, the mid-region, by comparison, exhibits a more flexiblefeel, allowing for better control of the puck on hard passes and shots.

Any of the above-described embodiments may be used alone or incombination with one another. Further, the hockey stick or hockey-stickblade may include additional features not described herein. Whileseveral embodiments have been shown and described, various changes andsubstitutions may of course be made, without departing from the spiritand scope of the invention. The invention, therefore, should not belimited, except by the following claims and their equivalents.

What is claimed is:
 1. A hockey-stick blade including a front face, anda rear face spaced from the front face in a lateral direction,comprising: a heel region; a toe region spaced from the heel region in alongitudinal direction; a mid-region located between the heel region andthe toe region; and an upper core element and a lower core elementpositioned between the front face and the rear face, wherein a firstreinforcing element is positioned directly on a lower surface anddirectly on front and rear faces of the upper core element and only on aportion of a second reinforcing element, and the second reinforcingelement is positioned directly on an upper surface and directly on frontand rear faces of the lower core element, and wherein at least one ofthe first reinforcing element and the second reinforcing element ispositioned only in the toe region.
 2. The hockey-stick blade of claim 1wherein the core elements are spaced apart from one another in avertical direction.
 3. The hockey-stick blade of claim 1, wherein thefirst and second reinforcing elements comprise fiber-reinforced plies.4. The hockey-stick blade of claim 1 wherein one of the firstreinforcing element and the second reinforcement element has a length inthe longitudinal direction that is greater than a length of the other ofthe first reinforcing element and the second reinforcing element in thelongitudinal direction.
 5. The hockey-stick blade of claim 1 wherein thefirst and second reinforcing elements are contained within the blade. 6.A hockey-stick blade including a front face, and a rear face spaced fromthe front face in a lateral direction, comprising: a heel region; a toeregion spaced from the heel region in a longitudinal direction; amid-region located between the heel region and the toe region; and aplurality of core elements positioned between the front face and therear face, wherein the plurality of core elements includes at least anupper core element and a lower core element, wherein a first reinforcingelement is positioned on a lower surface and directly on a front face ora rear face of the upper core element and on a second reinforcingelement, wherein the second reinforcing element is positioned on anupper surface and a front face or a rear face of the lower core element,and wherein at least one of the first reinforcing element and the secondreinforcing element is positioned only in the toe region.
 7. Thehockey-stick blade of claim 6 wherein the core elements are spaced apartfrom one another in a vertical direction.
 8. The hockey-stick blade ofclaim 6 wherein one of the first reinforcing element and the secondreinforcing element has a length in the longitudinal direction that isgreater than a length of the other of the first reinforcing element andthe second reinforcing element in the longitudinal direction.
 9. Ahockey-stick blade including a front face, and a rear face spaced fromthe front face in a lateral direction, comprising: a heel region; a toeregion spaced from the heel region in a longitudinal direction; amid-region located between the heel region and the toe region; and anupper core element and a lower core element positioned between the frontface and the rear face, wherein a first reinforcing element ispositioned on a lower surface and on front and rear faces of the uppercore element and only on a portion of a second reinforcing element, andthe second reinforcing element is positioned on an upper surface and onfront and rear faces of the lower core element, and wherein at least oneof the first reinforcing element and the second reinforcing element ispositioned only in the toe region.
 10. The hockey-stick blade of claim 9wherein the core elements are spaced apart from one another in avertical direction.
 11. The hockey-stick blade of claim 9, wherein thefirst and second reinforcing elements comprise fiber-reinforced plies.12. The hockey-stick blade of claim 9, wherein one of the firstreinforcing element and the second reinforcing element has a length inthe longitudinal direction that is greater than a length of the other ofthe first reinforcing element and the second reinforcing element in thelongitudinal direction.
 13. The hockey-stick blade of claim 9, whereinthe first and second reinforcing elements are contained within theblade.